Method for protecting a profile structural part of an aircraft against mechanical wear and/or mechanical impact

Abstract

To manufacture a protected profile structural part of a fuselage of an aircraft, a sealant mold having a mold cavity having a cross-section that matches a portion of the profile structural part on which the surface to be protected is disposed is prepared. The mold cavity is filled with uncured wet sealant which is subsequently cured into a cured sealant member. The cured sealant member is then attached to the finished structural profile part in a non-movable manner to form a protective liner on the surface to be protected and to generate the protected profile structural part.

1 . A method for manufacturing a protected profile structural part of a fuselage of an aircraft, the method comprising:
 a) providing a finished structural profile part, the finished structural profile part having a surface to be protected;   b) preparing a sealant mold having a mold cavity, wherein the mold cavity has a cross-section that matches a portion of the profile structural part on which the surface to be protected is disposed, such that a molded part made with the sealant mold can be attached to the portion of the profile structural part;   c) filling the mold cavity with uncured wet sealant, curing or letting cure the uncured wet sealant into a cured sealant member within the mold cavity and removing the cured sealant member from the sealant mold; and   d) attaching the cured sealant member to the finished structural profile part in a non-movable manner so as to form a protective liner on the surface to be protected and to generate the protected profile structural part.   
     
     
         2 . The method according to  claim 1 , wherein in step c) the curing is carried out at room temperature, in a temperature range from 15° C. to 28° C. 
     
     
         3 . The method according to  claim 1 , wherein in step c) the curing is carried out at or in at least one of a curing oven or autoclave at a temperature elevated above room temperature. 
     
     
         4 . The method according to  claim 1 , wherein step d) is performed after step c). 
     
     
         5 . The method according to  claim 1 , wherein the sealant mold comprises an injection opening that fluidly connects to the mold cavity, and in step c) the uncured wet sealant is filled into the mold cavity through the injection opening. 
     
     
         6 . The method according to  claim 5 , wherein the sealant mold comprises a discharge opening that fluidly connects to the mold cavity, and in step b) the uncured wet sealant is filled, preferably injected through the injection opening, into the mold cavity until the uncured wet sealant is discharged through the discharge opening. 
     
     
         7 . The method according to  claim 1 , wherein the finished structural profile part comprises a top portion that, when the finished structural profile part is installed on a skin of the fuselage, is spaced apart from the skin, and the surface to be protected is part of the top portion and faces away from the skin, wherein in step b) the mold cavity is prepared such that the cured sealant member is configured to cover the top portion of the finished structural profile part. 
     
     
         8 . The method according to  claim 1 , wherein the finished structural profile part comprises at least one lateral portion that, when the finished structural profile part is installed on a skin of the fuselage, is spaced apart from the skin, and the surface to be protected is part of each lateral portion and faces parallel to the skin, wherein in step b) the mold cavity is prepared such that the cured sealant member is configured to cover at least one lateral portion of the finished structural profile part. 
     
     
         9 . The method according to  claim 1 , wherein in step d) the cured sealant member is attached such that the cured sealant member cannot be removed in a non-destructive manner. 
     
     
         10 . The method according to  claim 1 , wherein in step c) the uncured wet sealant is a self-curing sealant. 
     
     
         11 . The method according to  claim 10 , wherein the wet sealant is chosen from a group consisting of polysulfide based sealant, polythioether based sealant, epoxy based sealant, and polyurethane based sealant. 
     
     
         12 . The method according to  claim 1 , wherein in step d) the cured sealant member is attached via a self-curing wet sealant. 
     
     
         13 . The method according to  claim 12 , wherein the self-curing wet sealant is chosen from a group consisting of polysulfide based sealant, polythioether based sealant, epoxy based sealant, and polyurethane based sealant. 
     
     
         14 . The method according to  claim 1 , wherein in step b) the uncured wet sealant is injected with an injection pressure of 0.5 bar to 10 bar. 
     
     
         15 . The method according to  claim 1 , wherein the method is performed at a temperature between 10° C. and 30° C. 
     
     
         16 . The method according to  claim 1 , wherein the sealant mold comprises or is made of a non-stick material that is configured such that in step c) the uncured wet sealant does not bond to the sealant mold. 
     
     
         17 . The method according to  claim 16 , wherein the non-stick material is chosen from a group consisting of a release agent, PTFE or a fluorosilicone.